Furniture assembly system and method

ABSTRACT

A furniture assembly system and method is presented. The furniture assembly comprising a plurality of components having a first and a second long rails. The first and the second long rails are joined to a first and second side or end rails to form a frame. A plurality of coupling modules, each is sized smaller than the frame is then fitted to the frame to form an assembled frame. This way, the furniture components may be packaged into groups so that each group does not exceed the weight and/or size restriction of a selected carrier or a transportation vehicle.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of a provisional U.S.application, Serial No. 60/187,815, filed Mar. 8, 2000.

FIELD OF THE INVENTION

[0002] This invention generally relates to a furniture system andmethod, and more particularly to a system and method for constructing,deconstructing and/or shipping a furniture assembly which may beotherwise too large and/or too heavy to ship when fully assembled.

BACKGROUND AND SUMMARY OF THE INVENTION

[0003] Although there are many shipping companies or commercial carrierssuch as, for example, United Parcel Service (UPS), Federal Express, andUnited Post Office Express Mail Service, available for shippingpackages, many of them impose a maximum size and/or weight restriction.Therefore, the present inventor recognizes that it is desirable to beable to provide furniture that can be constructed and packaged to meetthe maximum size and/or weight restriction of these carriers. Inaddition, this type of furniture will be advantageous for a typicalretail store buyer who may a regular transportation vehicle to take thefurniture home.

[0004] Therefore, the present invention provides an apparatus and methodfor reducing the size and/or weight of packaged furniture, such as, forexample, a futon frame. The present invention also provides an easy toassemble and an easy to ship furniture frame. Therefore, the presentinvention allows the furniture to be shipped using a conventionalshipper or carrier such as UPS, Federal Express, U.S. Post Office orusing a buyer's own vehicle for delivery.

[0005] In one aspect, a furniture assembly system and method ispresented. The furniture assembly comprising a plurality of componentshaving a first and a second long rails. The first and the second longrails are joined to a first and second side or end rails to form aframe. A plurality of coupling modules, each is sized smaller than theframe is then fitted to the frame to form an assembled frame. This way,the furniture components may be packaged into groups so that each groupdoes not exceed the weight and/or size restriction of a selected carrieror a transportation vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the drawing:

[0007]FIG. 1 is an exemplary furniture apparatus in accordance with theprinciples of the present invention.

[0008]FIG. 2 is another exemplary furniture apparatus in accordance withthe principles of the present invention.

[0009]FIG. 3 is a flow chart in accordance with the principles of thepresent invention.

DETAILED DESCRIPTION

[0010]FIG. 1 is an exemplary furniture assembly 1 according to theprinciples of the present invention. In particular, the exemplaryfurniture assembly 1 may be, for example, a futon frame, which comprisesa seat assembled portion 5 and back support assembled portion 8. Seatportion 5 may be attached to support portion 8 in, for example, asubstantially perpendicular fashion, using for example, well know meanssuch as connecting rods, screws, dowels or any other fasteners (notshown) to form a futon sofa frame. The portions may also be connectedfor example, side by side to form a large bed frame.

[0011] Each assembled seat portion or frame 5 or back support portion orframe 8 may be comprised of, for example, 2 long rails 10 on each sideof portion 5 or 8. In addition, 2 left and right side rails or end rails12 are joined to the long rails 10 by means such as for example, but notlimited to screws, dowels or any other fasteners. Portion 5 or 8 whenassembled thereby creates an assembled frame for which solidifyingsections or coupling modules 15 may be fitted, as to be described inmore detail below.

[0012] To accommodate solidifying sections or coupling modules 15, acoupling mechanism 16 is provided on each long rail 10 of portion 5 or8, for attaching coupling modules 15 to portion 5 or 8. A couplingmechanism may be for example, a cleat 16 as shown in FIG. 1, a slot, orany other mechanism which allows coupling modules 15 to be removablyattached and/or detached to and from long rails 10 of portion 5 or 8.Each coupling module 15 may therefore has pre-manufactured slots, cleatsor other complementary coupling means to allow its attachment to longrails 10.

[0013] In addition, coupling modules are preferably substantially rigidso that they may further strengthen seat or back portion 5 or 8, afterthey are attached thereto. As shown in FIG. 1, coupling modules 15 maycomprise of a solid material such as, but not limited to, for example,various types of natural woods, plywoods, manufactured boards, vinyl orplastic, etc.

[0014] In addition, coupling modules 15 may be of any size, but arepreferably sized to be smaller than seat or back portion 5 or 8. Forexample, FIG. 1 shows that coupling modules 15 are sized so that threemodules 15 may be fitted to a seat or back portion 5 or 8. In otheralternatives, coupling modules may be sized differently for a seat orback portion respectively, for esthetic and/or functional purposes.

[0015]FIG. 2 illustrates that besides being comprised of a solid pieceof material as discussed above, an exemplary coupling module 15-1 may beconstructed out of pieces of wood or metal frames 20, 21. In addition, acoupling mechanism may comprise, for example, an intruding piece whichmay be, for example, a rectangularity shaped insert 18 to be fitted intoan opening of another similarly shaped receiving piece 19 of a long rail10. Of course, other similar coupling means in different shapes and orsizes may also be used.

[0016] Furthermore, an exemplary coupling module 15-2 in FIG. 2 showsthat foam or other padding materials 14 may be added to coupling modules15 to serve as seating or back-supporting pads. This padding mayeliminate the need for a regular futon to be purchased, therefore mayfurther eliminate the weight, size and cost of the conventional futonfurniture assembly.

[0017]FIG. 3 illustrates a process according to the principles of theinvention. As discussed above and shown in step 301, furniture assembly1 shown in FIGS. 1 or 2 may be manufactured as components comprising of2 long rails 10, 2 side rails 12 and a plurality of coupling modules 15,15-1 or 15-2. In step 303, weight and/or size restriction of a selectedcarrier is checked. In step 305, components are packaged into groups sothat each group does not exceed the weight and/or size restriction. Instep 305, the components may be assembled by a purchaser at adestination to form completely assembled furniture.

[0018] Accordingly, the present invention provides an easy-to-assemble,easy-to-ship furniture assembly. The furniture assembly is reduced intoits subparts to permit shipping or transportation, and may provide analternative to, for example, a traditional futon frame and structure. Itwill be apparent to those skilled in the art, that although theinvention has been described in terms of specific examples,modifications and changes may be made to the disclosed embodimentswithout departing from the essence of the invention.

What is claimed is:
 1. A furniture frame, comprising: a first and asecond long rails; a first and a second side rails capable of beingjoined to said first and second long rails to form a frame; and aplurality of coupling modules, each is sized smaller than the frame. 2.The furniture frame of claim 1 wherein the plurality of coupling modulesare removably attached to the frame by a coupling mechanism to form anassembled frame.
 3. The furniture frame of claim 2 wherein the couplingmechanism comprising at least one of: 1) a cleat, 2) a slot, 3) a screw,and 4) an intruding piece on the first and second long rails.
 4. Thefurniture frame of claim 3 wherein the coupling mechanism furthercomprising at least one of: 1) a cleat, 2) a slot, 3) a screw, and 4) areceiving piece on the first and second side rails.
 5. The furnitureframe of claim 1 wherein the plurality of coupling modules comprisingsubstantially rigid material.
 6. The furniture of claim 5 wherein theplurality of coupling modules further comprising padding material. 7.The furniture of claim 1 wherein the plurality of coupling modules aresubstantially the same size.
 8. The furniture of claim 2 wherein thefurniture frame comprises more than one of the assembled frame.
 9. Amethod for shipping a furniture assembly to be assembled at adestination which when fully assembled exceeds one of weight restrictionand size restriction of a shipper, comprising the steps of:manufacturing the furniture assembly as separate components comprising:a first and a second long rails, a first and a second side rails capableof being joined to said first and second long rails to form a frame, anda plurality of coupling modules, each is sized smaller than the frame;and Packaging the separate components in groups such that none of thegroups exceeds the one of the weight restriction and size restriction ofthe shipper.
 10. The method of claim 10 further comprising the step of:attaching the plurality of coupling modules to the frame by a couplingmechanism to form an assembled frame at the destination.
 11. The methodof claim 10 wherein the coupling mechanism comprising at least oneof: 1) a cleat, 2) a slot, 3) a screw, and 4) a intruding piece on thefirst and second long rails.
 12. The method of claim 11 wherein thecoupling mechanism further comprising at least one of: 1) a cleat, 2) aslot, 3) a screw, and 4) a intruding piece on the first and second siderails.
 13. The method of claim 10 wherein the plurality of couplingmodules comprising substantially rigid material.
 14. The method of claim13 wherein the plurality of coupling modules further comprising paddingmaterial.
 15. The method of claim 10 wherein the plurality of couplingmodules are substantially the same size.
 16. The method of claim 10wherein the furniture assembly comprises more than one of the assembledframes
 17. A futon frame, comprising: a first and a second long rails; afirst and a second side rails capable of being joined to said first andsecond long rails to form a frame; and a plurality of coupling means,each is sized smaller than the frame and being removably attachable tothe frame by a coupling mechanism to form an assembled frame.
 18. Thefuton frame of claim 17 wherein the plurality of coupling means are ofsubstantially the same size.
 19. The futon frame of claim 18 wherein thefuton frame comprising more than one assembled frame.
 20. The furnitureframe of claim 19 wherein the coupling means are substantially rigid.